WORKSHOP MANUAL

Futura FHD2 / FMD2

Introduction

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Futura FHD2 / FMD2

Foreword
This workshop manual contains all the relevant
information to help when tracing and solving technical
problems, when making adjustments and when carrying
out repair work.
The book contains diagrams, system descriptions, fault
finding instructions and work instructions. It also contains
safety regulations, which must be strictly observed.

Experienced mechanics
The technical information and the explanations of the
repair work stated in this workshop manual have been
compiled with the utmost care.

Whilst compiling this workshop manual, it has been

assumed that the mechanic has the necessary
experience and has had the required education or
training to be able to carry out the work in a responsible
and safe manner.

Vehicle type.
The information in this manual has been updated until
the time of printing and only concerns the following
vehicle series:
Futura FHD2 / FMD2

In this manual, this series of vehicles is referred to as:

Futura FHD2 / FMD2

DD1008_01
 CONTENTS
Futura FHD2 / FMD2

Workshop manual introduction

Use of the workshop instructions ............... 1-1
General information ........................................ 1-1
Layout of the workshop instructions................ 1-1
How to use the workshop manual and the
system book.................................................... 1-2
Other documentation ...................................... 1-8
Main group layout ......................................... 2-1
Book numbering and contents .................... 3-1
Documentation Report Form ......................... -1

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Futura FHD2 / FMD2

Disclaimers

© 1518 VDL Bus & Coach bv, Valkenswaard,

The Netherlands.

In the interest of continuous product development VDL

Bus & Coach reserves the right to change specifications
or products at any time without prior notice.

No part of this publication may be reproduced and/or

published by printing, by photocopying, in digital format
or in any way whatsoever without the prior consent in
writing of VDL Bus & Coach.

This manual shall be governed by and applied in

accordance with the laws of the Netherlands.
Any dispute here under shall be referred to the decision
of the District Court of ’s-Hertogenbosch in the
Netherlands

Next remark is relevant if the text has been translated for

your convenience from the English original into an other
language.
A translation, however, can have the consequence that
differences of interpretation arise with respect to the
content and meaning of the text.
In all cases, therefore, the English version of this
document will be regarded exclusively as the single and
authentic source to establish the content and the
meaning of the text in case of a dispute.

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 WORKSHOP MANUAL INTRODUCTION
Futura FHD2 / FMD2

WORKSHOP MANUAL INTRODUCTION

0

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 WORKSHOP MANUAL INTRODUCTION
Futura FHD2 / FMD2

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 WORKSHOP MANUAL INTRODUCTION
Futura FHD2 / FMD2 Use of the workshop instructions

1. USE OF THE WORKSHOP INSTRUCTIONS

1.1 GENERAL INFORMATION

The workshop instructions can be divided into:
• Workshop manual
• A system book.

1.2 LAYOUT OF THE WORKSHOP

INSTRUCTIONS
1.2.1 WORKSHOP MANUAL

The workshop manual consists of a number of chapters in

which vehicle-orientated instructions are given, such as
removing and installing components, inspections, adjust-
ments, etc.

These instructions are based on a vehicle and the equipment

it had when it left the factory.
The vehicle series that these workshop instructions have
been written for include various vehicle types and designs.
It is, therefore, possible that these workshop instructions
contain text and diagrams that are not a true representation
of the situation that you encounter in your vehicle.

1.2.2 SYSTEM BOOKS

Each system (e.g. ECAS, fan drive, etc.) is described in a

separate document. The description includes additional
information and fault tracing.

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Use of the workshop instructions Futura FHD2 / FMD2

1.3 HOW TO USE THE WORKSHOP MANUAL

AND THE SYSTEM BOOK
1.3.1 WORKSHOP MANUAL

There is a workshop manual with vehicle-orientated instruc-

tions for every type of VDL Bus & Coach vehicle.

Main groups
Each vehicle meets the legal regulations in the country con-
cerned and is tuned for the expected operating conditions.

ILAz0038

The workshop manual consists of 10 main groups (0 to 9),

which each deal with a certain part of the vehicle.
The overview of the main groups shows which main group
deals with which part of the vehicle.

ILAz0156

Overview of the contents

The “Introduction” chapter of the workshop manual includes
an “Overview”, which shows all the main groups, subgroups
and contents pages with their publication dates.
This “Overview” can be used to check the completeness of
the workshop manual.

ILAz0157

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Page of contents in every main group

This contains all the subgroups in the main group. Each sub-
group has its own black square with a
number.

ILAz0158

The subgroup number is given in the black square (see arrow

B).

Each subgroup contains one or more chapters. The title of

the chapter is printed in bold.

The number of a chapter (see arrow A) consists of a chapter

number and a page number in a logical order (e.g. 3-2).

ILAz0159

Instructions page
The main group and the vehicle series are given in the top
left-hand corner of the header. The name of the subgroup
and the name of the chapter are given in the top right-hand
corner of the header.

ILAz0160

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Use of the workshop instructions Futura FHD2 / FMD2

Page number and document number

The page number consists of two positions, i.e. the chapter
number and the page number (e.g. 1-5).

The document number is given in the bottom left-hand corner

or bottom right-hand corner of every page (e.g. DD043800).

ILAz0161

Cross references
Cross references refer to a certain piece of text. A cross ref-
erence is indicated as shown in the example given below.
0 - 3.2 Tightening torques (3 - 2).

If a cross reference refers to a different main group, then it

will be preceded by the number of the main group.
For example:
See Group 2, 0 - 3.2 Tightening torques (3 - 2).

ILAz0046
A Main group (0 to 9).
B Subgroup (with a black square).
C Chapter (e.g. 3.2).
D Description
E Chapter number (3) and page number (2).

- Cross references are given in blue.

ILAz0162

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1.3.2 SYSTEM BOOKS

System books are available for the various systems used in

the VDL Bus & Coach vehicles.

ILAz0038

Contents page in the system book

This contains all the subgroups in the system book. Each
subgroup has its own black square with a
number.

ILAz0158

The subgroup number is given in the black square (see arrow

B).

Each subgroup contains one or more chapters. The title of

the chapter is printed in bold.

The number of a chapter (see arrow A) consists of a chapter

number and a page number in a logical order (e.g. 3-2).

ILAz0159

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Use of the workshop instructions Futura FHD2 / FMD2

Instructions page
The vehicle series is given in the top left-hand corner of the
header. The name of the subgroup and the name of the
chapter are given in the top right-hand corner of the header.

ILAz0160

Page number and document number

The page number consists of two positions, i.e. the chapter
number and the page number (e.g. 1-5).

The document number is given in the bottom left-hand corner

or bottom right-hand corner of every page (e.g. DD043800).

ILAz0161

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Futura FHD2 / FMD2 Use of the workshop instructions

Cross references
Cross references refer to a certain piece of text. A cross ref-
erence is indicated as shown in the example given below.
0 - 3.2 Tightening torques (3 - 2).

If a cross reference refers to a different main group, then it

will be preceded by the number of the main group.
For example:
See Group 2, 0 - 3.2 Tightening torque (3 - 2).

ILAz0046
A Main group (0 to 9).
B Subgroup (with a black square).
C Chapter (e.g. 3.2).
D Description
E Chapter number (3) and page number (2).

- Cross references are given in blue.

ILAz0162

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1.4 OTHER DOCUMENTATION

Only a brief overview of the documentation has been given
below. For a complete overview, please contact the VDL Bus
& Coach Service department.

Technical information
Important alterations concerning the workshop instructions
are distributed by means of Service Bulletins (see the Basis
website of VDL Bus & Coach).
These Service Bulletins must be added to the workshop
instructions.
The Service Bulletins become invalid once the information
they contain has been included in the workshop instructions
by VDL Bus & Coach.

Maintenance forms and maintenance book

There is a maintenance form and maintenance book for
every type of VDL Bus & Coach vehicle.
• The maintenance form contains all the maintenance
activities and time intervals of these activities.
• The maintenance book describes how the maintenance
work must be carried out.

Driver’s instruction manual

This manual is intended to help the driver make the best use
of the vehicle.

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Futura FHD2 / FMD2 Main group layout

2. MAIN GROUP LAYOUT

0 1

2 3

4 5

6 7

8 9
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Main group layout Futura FHD2 / FMD2

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Futura FHD2 / FMD2 Book numbering and contents

3. BOOK NUMBERING AND CONTENTS

The overview of the workshop manual contains all the

main groups with their publication dates and a description of
all the subgroups.

This overview can be used to check the completeness of the

workshop manual.
Main group Sub-group description Document no. Date

0 Contents of main group 0 DD1020_XX 1408

- General information
- Safety instructions
- Diagnosis
- Repair guidelines
- Liquid and lubricant guidelines
- Cleaning regulations
- Storage and preservation
- Paint treatment
- Instructions for jacking up, hoisting and supporting the
vehicle

1 Contents of main group 1 DD1021_XX 1408

- General specifications
- Door systems
- Wheelchair ramp
- Seats
- Windscreen wiper/washer installation
- Climate system
- Roof hatch
- Engine compartment fire extinguisher installation
- Replacing bodywork components
- Electrotechnical information
- Chassis and bodywork protection
- Glue/adhesive products

2 Contents of main group 2 with MX-11 DD1022_XX 1518

- Technical information
- Diagnosis
- Engine
- Cooling system
- Hydraulic fan drive
- Sump filling unit
- Air conditioning compressor drive

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Book numbering and contents Futura FHD2 / FMD2

Main group Sub-group description Document no. Date

2 Contents of main group 2 with MX-13 DD1682_XX 1518

- Technical information
- Diagnosis
- Engine
- Cooling system
- Hydraulic fan drive
- Sump filling unit
- Air conditioning compressor drive

3 Contents of main group 3 DD1023_XX 1408

- Technical information
- Diagnosis
- Voith Diwa.5 automatic gearbox
- Drive shafts

4 Contents of main group 4 with MX-11 DD1024_XX 1408

- Technical information
- Diagnosis
- Fuel system
- Intake/exhaust system
- Throttle control
- Exhaust gas after-treatment system
- Water heater

4 Contents of main group 4 with MX-13 DD1684_XX 1518

- Technical information
- Diagnosis
- Fuel system
- Intake/exhaust system
- Throttle control
- Exhaust gas after-treatment system
- Water heater

5 Contents of main group 5 DD1025_XX 1408

- Technical information
- Diagnosis
- Fault tracing method
- Measuring and diagnosis equipment
- Components
- Wiring repairs
- Batteries

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Main group Sub-group description Document no. Date

- Electrical installation
- Reading the diagrams
- System descriptions
- Service diagrams

6 Contents of main group 6 DD1026_XX 1408

- Technical information
- Diagnosis
- Brake diagram
- Operation of the brake components
- Brake system and components

7 Contents of main group 7 DD1027_XX 1408

- Technical information
- Diagnosis
- Steering mechanism – general information
- Steering box
- Steering pump
- Lines and reservoir
- Bevel box
- Steering column
- Front axle

8 Contents of main group 8 DD1028_XX 1408

- Technical information
- Diagnosis
- Safety
- Special tools
- Dana 09.24 rear axle

9 Contents of main group 9 DD1029_XX 1408

- Technical information
- Diagnosis
- Chassis
- Shock absorbers
- Stabilizers and torque rods
- Pneumatic suspension
- Rear axle alignment
- Central lubrication system

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Futura FHD2 / FMD2

DOCUMENTATION REPORT FORM

If you have any suggestions and/or comments regarding

our documentation, or if you have observed any errors,
then please complete this form and return it to:
VDL Bus & Coach
Training and Documentation Company name : ..............................................................

P.O. Box 298

Name : ..............................................................
5500 AG Veldhoven
The Netherlands
Signature : .................................................................
Fax: +31 (0)40 2048822

Chassis number .........................................................

Concerns document order number: ......................................................... Version: .........................................

Driver Climate system

Type of document: Maintenance Electrical circuit diagram

(tick what is applicable) Workshop Training

Components Other
Linguistic (description is not Error in the technical information
Type of error: Illustrations
correct) (values)
(tick what is applicable)

Additional information: ..........................................................................................................................................
(texts, page number, etc.) ..........................................................................................................................................
..........................................................................................................................................
..........................................................................................................................................

Your report will be taken seriously by VDL Bus & Coach

and, if necessary, will be immediately incorporated in the
document.

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Documentation Report Form Futura FHD2 / FMD2

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